Description

TheABB PM865K01 (3BSE031151R1)is a high-integrity, redundant-capable central processing unit (CPU) module for ABB’sAC 800Mprogrammable automation controller within theSystem 800xAdistributed control platform. Designed for mission-critical applications in power generation, oil & gas, and chemical processing, it delivers deterministic real-time control, seamless failover, and integrated safety functionality up toIEC 61508 SIL3.

As part of ABB’sAbility™digital offering, thePM865K01supports secure remote access, predictive diagnostics, and lifecycle management—ensuring decades-long operational continuity in capital-intensive industries.

Application Scenarios

At a 2,000 MW coal-fired power plant in Germany undergoing digital transformation, legacy controllers caused 4–6 unscheduled outages annually due to single-point CPU failures. Engineers deployeddual ABB PM865K01 3BSE031151R1modules in redundant configuration across all boiler and turbine control loops. During a grid instability event that triggered rapid load shedding, the primaryPM865K01detected an internal memory parity error and automatically transferred control to the secondary unit in<50 ms—with zero process interruption. Over three years, unplanned downtime dropped by92%, saving over €8 million in avoided penalties and lost generation.

Parameter

Main Parameters

Value/Description

Product Model

PM865K01

ABB Part Number

3BSE031151R1

Manufacturer

ABB

Product Category

Redundant CPU Module for AC 800M Controller

Processor

Dual-core ARM Cortex-A9 (lockstep for safety tasks)

Memory

512 MB DDR3 SDRAM, 4 GB eMMC flash (application + logs)

Redundancy Mode

Full hot-standby redundancy (primary/secondary sync via optical link)

Scan Cycle Time

As low as5 msfor logic execution

Communication Interfaces

• Dual 10/100/1000BASE-T Ethernet (Modbus TCP, OPC UA, IEC 61850)

• Profibus DP/PA, Foundation Fieldbus H1 (via CI854A or similar comms modules)

• Internal IONET for I/O module synchronization

Operating System

ABB Extended VxWorks RTOS with safety kernel

Certifications

IEC 61508 SIL3, IEC 61511, API 670, CE, UL 61010, ATEX (Zone 2 optional)

Operating Temperature

0°C to +60°C(derated above 50°C); conformal coating available

Power Supply

Powered via backplane from PPD113 or PPD112 power modules

Diagnostics

Built-in self-test (BIST), watchdog, memory ECC, real-time health monitoring via 800xA

Note: The optical redundancy link ensures galvanic isolation between CPUs—critical in high-noise environments like switchyards or compressor stations.

Technical Principles and Innovative Values

Innovation Point 1: True Hot-Standby Redundancy with State Sync– ThePM865K01continuously synchronizes application state, I/O images, and timer values between primary and secondary units via a dedicatedfiber-optic link, enabling bumpless switchover during faults—no reinitialization or process reset required.

Innovation Point 2: Integrated SIL3 Safety Logic Solver– Unlike add-on safety systems, thePM865K01executes standard control and safety instrumented functions (SIFs) on the same hardware—reducing footprint, wiring, and validation effort while meetingIEC 61508 SIL3requirements.

Innovation Point 3: Cyber-Hardened Architecture– Supportsrole-based access control (RBAC), secure boot, encrypted firmware updates, and network segmentation—aligning withNERC CIP,IEC 62443, andISO/IEC 27001for critical infrastructure protection.

Innovation Point 4: Lifecycle Transparency via 800xA– Operators view CPU health metrics (memory usage, scan load, temperature) directly in System 800xA HMI, enabling predictive maintenance and reducing mean time to repair (MTTR) by up to 60%.

Innovation Point 5: Backward Compatibility– Fully compatible with existing AC 800M I/O modules (e.g., AI810, DI810) and application logic—allowing brownfield sites to upgrade CPUs without rewiring or reprogramming.

Application Cases and Industry Value

In a Middle Eastern LNG export terminal, thePM865K01replaced aging PM860 controllers managing cryogenic transfer pumps. Its SIL3 capability allowed integration of emergency shutdown (ESD) logic directly into the process controller—eliminating a separate Triconex system and saving $1.8 million in capital costs. During a simulated flare event, thePM865K01tripped valves within8 ms, well below the 100 ms API 670 requirement.

Similarly, at a Scandinavian district heating utility, thePM865K01’s low scan cycle enabled tighter combustion control, reducing NOx emissions by12%and improving fuel efficiency—contributing to EU environmental compliance targets.

Related Product Combination Solutions

PPD113B01-10-150000 (3BHE023784R1023): 10A 24VDC power supply—powersPM865K01in redundant racks

TB820V (3BSE013204R1): Terminal base—connects field wiring to I/O modules controlled byPM865K01

CI854A (3BSE018192R1): Communication module—adds PROFIBUS/Modbus support toPM865K01system

AI810 (3BSE008516R1): Analog input module—for pressure, temp, flow signals processed byPM865K01

System 800xA Engineering Workplace: Configures, tests, and monitorsPM865K01applications

PM865K02 (3BSE031152R1): Alternate variant with enhanced cybersecurity features

Redundancy Optical Cable (3BSE032250R1): Connects twoPM865K01units for sync

Control Builder M: ABB’s IEC 61131-3 programming tool—used to develop logic forPM865K01

Installation, Maintenance, and Full-Cycle Support

Install theABB PM865K01 3BSE031151R1in a designated slot of an AC 800M rail-mounted chassis. For redundancy, install two units side-by-side and connect them via theoptical redundancy portusing ABB-approved fiber cable. All configuration (IP, redundancy role, application logic) is handled throughControl Builder MandSystem 800xA—no DIP switches or manual addressing.

Maintenance best practices:

ReviewCPU load and memory usageweekly via 800xA

Verifyredundancy sync statusmonthly

Replace backup battery (if equipped) every 5 years

In redundant mode, faulty units can behot-swappedwithout process interruption

We guarantee everyABB PM865K01 3BSE031151R1is100% original

, factory-sealed or fully refurbished to ABB specifications, and tested on live AC 800M platforms for:

✅ Boot integrity

✅ Redundancy failover (<100 ms)

✅ Ethernet communication

✅ I/O scan stability under load

Each unit includes a12-month warranty, full compliance documentation (CE, SIL3 certificate), and access to ABB-certified technical support.

Contact usfor a tailored solution that ensures your process remains safe, efficient, and future-ready—powered by the proven reliability of theABB PM865K01.